Tubular heating elements are essential components in many appliances and industrial equipment. They are typically made using a fine coil of nichrome (NiCr) resistance heating alloy wire. This coil is placed inside a metallic tube, usually made of copper or stainless steel alloys like Incoloy. The coil is insulated with magnesium oxide powder to ensure efficient heat transfer and prevent short circuits. To protect the hygroscopic insulator from moisture, the ends of the tube are sealed with beads made of insulating materials such as ceramic or silicone rubber. The tube is then drawn through a die to compress the magnesium oxide powder, enhancing its thermal conductivity. These elements can be straight or bent into specific shapes to fit various appliances such as electric stoves, ovens, and coffee makers.
How are Tubular Heating Elements Made? 5 Key Steps Explained
1. Selection of Materials
The choice of materials is crucial for the performance and longevity of the heating element. Nichrome is selected for its high resistance and ability to withstand high temperatures without oxidizing. The metallic tube, often made of copper or stainless steel alloys, provides structural integrity and good thermal conductivity.
2. Assembly of Coil and Insulation
The nichrome coil is carefully placed inside the metallic tube, and magnesium oxide powder is filled around it. This powder acts as an insulator and conductor, ensuring that the heat generated by the coil is efficiently transferred to the surface of the tube.
3. Sealing and Compression
To prevent the ingress of moisture, which could degrade the performance of the magnesium oxide insulation, the ends of the tube are sealed with ceramic or silicone rubber beads. The tube is then compressed, typically by drawing it through a die, to compact the magnesium oxide and optimize its insulating and conductive properties.
4. Forming and Installation
Depending on the application, the tubular element may be left as a straight rod or bent into various shapes. This flexibility allows the elements to be integrated into a wide range of appliances, from toaster ovens to industrial heaters.
5. Quality Control and Testing
Each element undergoes rigorous testing to ensure it meets the required specifications for electrical resistance, thermal efficiency, and durability. This step is crucial to guarantee the safety and performance of the heating elements in their final applications.
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